LUBRICATION SYSTEM

Page
DESCRIPTION .................................................... LU-2
TROUBLESHOOTING ........................................ LU-4
OIL PRESSURE CHECK ........................................ LU-4
REPLACEMENT OF ENGINE OIL
AND OIL FILTER ........................................ LU-5
OIL PUMP .......................................................... LU-7
OIL COOLER AND RELIEF
VALVE (7M-GTE) ........................................ LU-15
LU-2 LUBRICATION SYSTEM - Description

DESCRIPTION
A fully pressurized, fully filtered lubrication system has been adopted for this engine

-Oil
Jet

PISTONS
t

1 CYLINDER HEAD 1
C

!
I I
I RELIEF V A L V E O I L PUMP
" OIL COOLER

O I L STRAINER t

i i t i
1 O I L PAN
 LUBRICATION SYSTEM - Description

A pressure feeding lubrication system has been OIL FILTER

adopted t o supply oil t o the moving parts of this
engine. The lubrication system consists of an oil
pan, oil pump, oil filter and other external parts
which supply oil t o the moving parts in the engine
block. The oil circuit is shown in the illustration at
the top of the previous page. Oil from the oil pan
is pumped up by the oil pump. After it passes
through the oil filter, i t is fed through the various
oil holes in the crankshaft and cylinder block. A f -
ter passing through the cylinder block and perform-
ing its lubricating function, the oil is returned by
gravity t o the oil pan. A dipstick on the side of the
cylinder block is provided t~ check the oil level.
OIL PUMP
The oil pump pumps up oil from the oil pan and
sends it under pressure t o the various parts of the
engine. An oil strainer is mounted in front of the
inlet t o the oil pump. The oil pump itself is a gear
pump, which uses a drive gear and driven gear in-
side the pump body. When the drive gear rotates,
the driven gear rotates in the opposite direction.
When the gear teeth disengage oil is drawn in, and
when the gear teeth engage oil is discharged.
The oil filter is a full flow type filter w i t h a built-
in paper filter element. Particles of metal from wear,
airborne dirt, carbon and other impurities can get
in the oil during use and could cause accelerated
wear or siezing if allowed t o circulate through the
engine. The oil filter, integrated into the oil line, re-
moves these impurities as the oil passes through
it. The filter is mounted outside the engine t o sim-
plify replacement of the filter element. A relief valve
is also included ahead of the filter element t o relieve
the high oil pressure in case the filter element be-
comes clogged with impurities. The relief valve
opens when the oil pressure overpowers the force
of the spring. Oil passing through the relief valve
bypasses the oil filter and flows directly into the
main oil hole in the engine.

OIL PRESSURE REGULATOR

At high engine speeds, the engine oil supplied by
the oil pump exceeds the capacity of the engine t o
utilize it. For that reason, the oil pressure regulator
works t o prevent an oversupply of oil. During nor-
mal oil supply, a coil spring and valve keep the
bypass closed, but when too much oil is being fed,
the pressure becomes extremely high, overpower-
ing the force of the spring and opening the valves.
This allows the excess oil t o flow through the valve
and return t o the oil pan.
 LU-4 LUBRICATION SYSTEM - Troubleshooting, Oil Pressure Check

TROUBLESHOOTING
1 Problem Possible cause 1 Remedy Page

C y l i n d e r head, c y l i n d e r b l o c k o r o i l p u m p Repair as necessary

b o d y damaged o r cracked
O i l seal f a u l t y Replace o i l seal
Gasket f a u l t y Replace gasket

O i l leakage Repair as necessary

Relief valve f a u l t y Repair relief valve
Oil pump faulty Repair o i l p u m p
Engine o i l p o o r q u a l i t y Replace engine o i l
Crankshaft bearing f a u l t y Replace bearing
C o n n e c t i n g r o d bearing f a u l t y Replace bearing
O i l f i l t e r clogged Replace o i l f i l t e r

H i g h o i l pressure Relief valve f a u l t y Repair relief valve

OIL PRESSURE CHECK

R e c o m m e n d e d Viscosity (SAE)
CHECK OIL QUALITY
Check the oil for deterioration, entry of water, discoloring
or thinning.
If oil quality is poor, replace.
Use API grade SG, multigrade, fuel-efficient and recom-
TEMPERATURE RANGE ANTICIPATED BEFORE mended viscosity oil.
NEXT O I L CHANGE
LU0884

CHECK OIL LEVEL

The oil level should be between the "L" and "F" marks
on the dipstick.
If low, check for leakage and add oil up t o the "F" mark.

REMOVE OIL PRESSURE SENDER GAUGE

INSTALL OIL PRESSURE GAUGE

START ENGINE
Start engine and warm it up t o normal operating tem-
perature.

MEASURE OIL PRESSURE

Oil
Oil pressure:
A t idle speed 0 . 3 kg/cm2 ( 4 . 3 psi, 2 9 kPa)
or more
At 3 , 0 0 0 rpm 2 . 5 - 5 . 0 kg/cm2
(36 - 71 psi, 2 4 5 - 4 9 0 kPa)
HINT: Check for oil leakage after reinstalling the oil pres-
sure sender gauge.
LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter LU-5

REPLACEMENT OF ENGINE OIL AND

OIL FILTER
NOTICE:
Prolonged and repeated contact with mineral oil will result
in the removal of natural fats from the skin, leading to dry-
ness, irritation and dermatitis. In addition, used engine oil con-
tains potentially harmful contaminants which may cause skin
cancer.
Adequate means of skin protection and washing facilities
should be provided.
Care should be taken, therefore, when changing engine oil,
t o minimize the frequency and length of time your skin is ex-
posed t o used engine oil. Protective clothing and gloves, that
cannot be penetrated by oil, should be worn. The skin should
be thoroughly washed with soap and water, or use water-
less hand cleaner, to remove any used engine oil. Do not use
gasoline, thinners, or solvents.
In order to preserve the environment, used oil must be di-
sposed of only at designated disposal sites.

1. DRAIN ENGINE OIL

(a) Remove the oil filler cap.
(b) Remove the oil drain plug and drain the oil into a con-
tainer.

2. REPLACE OIL FILTER

(a) Using SST, remove the oil filter (located on right side
of the engine block).
SST 09228-07500

HINT (7M-GTE): Remove the oil filter taking it over the

engine mounting bracket and down between the bracket
and No. 1 suspension crossmember.
LU-6 LUBRICATION SYSTEM - Replacement of Engine Oil and Oil Filter

( b ) Clean and check the oil filter installation surface.

( c ) Apply clean engine oil t o the gasket of the new oil
filter.

(d) Lightly screw in the oil filter until you feel resistance.
(e) Then, using SST, tighten the oil filter an extra 314 turn.
SST 09228-07500

3. FILL WITH ENGINE OIL

(a) Clean and install the oil drain plug with a new gasket.
Torque: 3 5 0 kg-cm ( 2 5 ft-lb, 3 4 N - m )
(b) Fill the engine w i t h new oil API grade SG, multigrade,
fuel-efficient and recommended viscosity oil.
Oil capacity (7M-GE):
Dry fill
4.9 liters (5.2 US qts, 4.3 Imp. qts)
Drain and refill
W/O Oil filter change
4.1 liters (4.3 US qts. 3.6 Imp. qts)
W/ Oil filter change
4.4 liters (4.7 US qts, 4.4 Imp. q t s l
Oil capacity (7M-GTE):
Dry fill
5.1 liters ( 5 . 4 US qts, 4.5 Imp. qts)
Drain and refill
W / O Oil filter change
4.1 liters (4.3 US qts, 3.6 Imp. qts)
W / Oil filter change
4 . 4 liters (4.7 US qts, 3.9 Imp. qts)

4. START ENGINE AND CHECK FOR LEAKS

5. RECHECK ENGINE OIL LEVER (See page LU-4)

 LUBRICATION SYSTEM - Oil Pump LU-7

OIL PUMP
COMPONENTS

-
B Snap Ring
S~acer
Key 4
@-o
li Pump Shaft Drive Gear

+ Union Bolt

Lock Washer
Oil Pump Outlet Pipe

Drive
Oil 1I
Shaft
Pump
Oil Pump
Driven Gear

Spring

Oil Pump Cover

+ Non-reusable part

REMOVAL OF OIL PUMP

REMOVE HOOD

REMOVE ENGINE UNDER COVER

DRAIN ENGINE OIL

WT)
REMOVE A/T OIL COOLER HOSE CLAMP

REMOVE NO. 1 FRONT SUSPENSION CROSSMEMBER

R E M O V E E X H A U S T FRONT PIPE BRACKET A N D

STIFFENER PLATES

(7M-GTE)
DISCONNECT ENGINE OIL COOLER HOSE FROM OIL PAN
LU-8 LUBRICATION SYSTEM - Oil Pump

8. REMOVE BRAKE HOSE BRACKETS AND CLIPS

9. DISCONNECT INTERMEDIATE SHAFT

Loosen the bolt, disconnect the intermediate shaft

1 0 . DISCONNECT STABILIZER BAR LINKS FROM LOWER

ARMS

11. REMOVE ENGINE MOUNTING NUTS AND WASHERS

Attach the engine hoist chain t o the t w o engine hangers.

12. REMOVE TEMS ACTUATOR

13. REMOVE SHOCK ABSORBERS FROM BODY

14. DISCONNECT FRONT SUSPENSION MEMBER

(a) Hold the front suspension member w i t h a jack.
( b ) Remove the t w o bolts and four nuts.
LUBRICATION SYSTEM - Oil Pump LU-9

(c) Lower the front suspension member, hold the m e m -

ber w i t h safety stands.

15. REMOVE OIL PAN

(a) Remove the t w e n t y t w o bolts and four nuts.
(b) Using SST and a brass bar, separate the oil pan f r o m
the cylinder block.
SST 09032-001000
HINT: W h e n removing the oil pan, be careful n o t t o
damage the oil pan flange.

16. REMOVE OIL PUMP

(a) Loosen the union nut.
(b) Remove the bolts and oil pump.

DISASSEMBLY OF OIL PUMP

1. REMOVE OIL STRAINER A N D OUTLET PIPE
(a) Remove the t w o bolts, oil strainer and O-ring.
(b) Remove the union bolt, lock washer, oil pump outlet
pipe and gasket.

2. DISASSEMBLY OIL PUMP

(a) Unscrew the relief valve plug, spring and relief valve.
(b) Remove the five bolts, oil pump cover and driven gear.
(c) Remove the snap ring, shaft gear, key, spacer and
drive shaft.
LU-10 LUBRICATION SYSTEM - Oil Pump

INSPECTION OF OIL PUMP

INSPECT RELIEF VALVE
Coat the valve w i t h engine oil and check that it falls smooth-
ly into the valve hole by its o w n weight.
If it does not, replace the relief valve. If necessary, replace
the oil pump assembly.

INSPECT BODY CLEARANCE

Using a thickness gauge, measure the clearance between
the driven gear and body.
Standard clearance:0 . 1 0 5 - 0 . 1 7 5 mm
( 0 . 0 0 4 1 - 0 . 0 0 6 9 in.)
Maximum clearance: 0 . 2 mm ( 0 . 0 0 8 in.)
If the clearance is greater than maximum, replace the drive
gear and/or body.

INSPECT GEAR BACKLASH

Using a thickness gauge, measure the backlash as shown.
Standard backlash: 0 . 5 - 0 . 6 mm
( 0 . 0 2 0 - 0 . 0 2 4 in.)
Maximum backlash: 0 . 9 mm ( 0 . 0 3 5 in.)
If the backlash is greater than maximum, replace the drive
shaft and/or driven gear.

INSPECT SIDE CLEARANCE

Using a thickness gauge and flat block, measure the side
clearance as shown.
Standard clearance: 0 . 0 3 - 0 . 0 9 mm
( 0 . 0 0 12 - 0 . 0 0 3 5 in.)
Maximum clearance: 0 . 1 5 mrn ( 0 . 0 0 5 9 in.)
If the clearance is greater than maximum, replace the drive
shaft and driven gear and/or body.
LUBRICATION SYSTEM - Oil Pump LU-11

ASSEMBLY OF OIL PUMP

(See page LU-7)
ASSEMBLY OIL PUMP
(a) lnstall the drive shaft, spacer, key, shaft gear and snap
ring.
(b) lnstall the driven gear and pump cover w i t h the five
bolts.
Torque: 7 5 kg-cm ( 6 5 in.-lb, 7 . 4 N - m )
(c) lnstall the relief valve and spring in the cover, and
screw o n the relief valve plug.
Torque: 3 7 5 kg-cm ( 2 7 ft-lb, 3 7 N-rn)

OPERATION CHECK OF OIL PUMP

CHECK PUMP OPERATION
(a) Immerse the suction end o f the pump into clean en-
gine oil and turn the shaft counterclockwise. Oil should
come out of the discharge hole.

( b ) Close the discharge hole w i t h your thumb, and turn

the shaft as before. The shaft should be difficult t o
turn.

INSTALL OIL PUMP STRAINER

(a) lnstall a n e w O-ring t o oil p u m p strainer.
(b) lnstall the oil pump strainer w i t h the t w o bolts.
Torque: 130 kg-cm (9 ft-lb, 1 3 N - m )

INSTALL OIL PUMP OUTLET PIPE

lnstall the oil pump outlet pipe w i t h a n e w lock washer,
gasket and the union bolt. Finger tighten the union bolt.
LU-12 LUBRICATION SYSTEM - Oil Pump

INSTALLATION OF OIL PUMP

(See page LU-7)
1. INSTALL OIL PUMP
(a) Install the oil pump with the bolt. Torque the bolt.
Torque: 2 2 0 kg-cm ( 16 ft-lb, 2 2 N - m )

(b) Install the mount bolt holding the oil pump strainer stay
t o block.
Torque: 6 0 kg-cm ( 5 2 in-lb, 5.9 N - m )

(c) Connect the outlet pipe with the union bolt.

Torque the union bolt and nut.
Torque: 3 5 0 kg-cm ( 2 5 ft-lb, 3 4 N - m )
(dl Stake the lock washer.

2. INSTALL OIL PAN

(a) Remove any packing material and be careful not t o
drop the oil on the contacting surfaces of the oil pan
and cylinder block.
Using a razor blade and gasket scraper, remove all
the packing (FIPG) material from the gasket
surfaces.
Thoroughly clean all components t o remove all the
loose material.
Clean both sealing surfaces w i t h a non-residue
solvent.
NOTICE: Do not use a solvent which will affect the paint-
ed surfaces.
 LUBRICATION SYSTEM - Oil P u m ~ LU-13

(b) Apply seal packing to the cylinder block installing sur-

face of the oil pan.
Seal packing: Part No. 08826-00080 or equivalent
(c) Install the oil pan over the studs on the block with the
twenty four bolts and t w o nuts.
Torque the bolts and nuts.
Torque: 130 kg-cm (9 ft-lb, 13 N.m)

*
A-A B--
,-
B C--C

3. INSTALL FRONT SUSPENSION MEMBER

Install the front suspension member to the body.
Torque: 1,300 kg-cm (94 ft-lb, 127 N.m)

4. INSTALL SHOCK ABSORBERS TO BODY

Install the shock absorber t o the body with the three nuts,
torque the nuts.
Torque: 360 kg-cm (26 ft-lb, 35 N.m)

5. INSTALL TEMS ACTUATOR

6. INSTALL ENGINE MOUNTING WASHERS AND NUTS

7. CONNECT STABILIZER BAR LINKS TO LOWER ARM

Torque: 650 kg-cm (47 ft-lb, 64 N.m)

8. CONNECT INTERMEDIATE SHAFT

Connect the intermediate shaft, torque the bolts.
Torque: 330 kg-cm (24 ft-lb, 32 N.m)
LU-14 LUBRICATION SYSTEM - Oil Pump

9. INSTALL BRAKE HOSE BRACKETS AND CLIPS

10. (7M-GTE)
CONNECT ENGINE OIL COOLER HOSE TO OIL PAN WlTH
NEW GASKETS

1 1. INSTALL STIFFENER PLATES AND EXHAUST FRONT PIPE

BRACKET

12. INSTALL NO. 1 FRONT SUSPENSION CROSS MEMBER

Torque: 9 3 0 kg-cm ( 6 7 ft-lb, 9 1 N - m )

13. (A/T)
INSTALL A / T OIL COOLER HOSE CLAMP

14. FILL WlTH ENGINE OIL

(See page LU-5)

15. INSTALL HOOD

16. START ENGINE AND CHECK FOR LEAKS

17. INSTALL ENGINE UNDER COVER

18. INSPECTION OF FRONT WHEEL ALIGNMENT

(See page FA-3)
 LUBRICATION SYSTEM - Oil Cooler and Relief Valve (7M-GTE) LU-15

OIL COOLER A N D RELIEF V A L V E

COMPONENTS

Union Bolt
6 Gasket ,Oli Filter BIracket

Valve
Relief Valve Plug
Spring w
+ Gasket L --
-/-1

No. 1 Oil Cooler Bracket ea

-Oil Filter
W Bracket))
No. 1 Oil Cooler Hose / + Gasket
No. 2 Oil Cooler Hose

-Oil Cooler

No. 3 Oil Cooler Hose

b Non-reusable part No. 3 Oil Cooler Hose

LU0576

REMOVAL OF OIL FILTER BRACKET

1. DRAIN ENGINE OIL

2. REMOVE N 0 . 4 AIR CLEANER PIPE WITH N O . l AND N 0 . 2

AIR CLEANER HOSES

3. REMOVE N 0 . 7 AIR CLEANER HOSE

(a) Disconnect the air hoses from ISC pipe, air intake con-
nector and PVC pipe.
( b ) Disconnect the air f l o w meter connector.
(c) Loosen the t w o clamps and unlock the air cleaner case
clip.
(dl Remove the bolt and No.7 air cleaner hose.
(el Disconnect the PS idle u p air hose.
LU-16 LUBRICATION SYSTEM - Oil Cooler and Relief Valve (7M-GTE)

4. REMOVE OIL FILTER BRACKET

(a) Disconnect the oil hose.

(b) Remove t h e union bolt, gasket, oil filter bracket and

O-ring.

REMOVAL OF RELIEF VALVE

1. REMOVE OIL FILTER
(See page LU-5)

2. REMOVE RELIEF VALVE

(a) Remove the relief valve plug and gasket.

(b) Remove the spring and relief valve.

INSPECTION OF RELIEF VALVE

Coat the valve w i t h engine oil and check that it falls smooth-
l y into t h e valve hole b y its o w n weight.
If i t does not, replace the relief valve. If necessary, replace
the oil filter bracket assembly.
LUBRICATION SYSTEM - Oil Cooler and Relief Valve (7M-GTE) LU-17

INSTALLATION OF RELIEF VALVE

1. INSTALL RELIEF VALVE
(a) Install the relief valve and spring.

(b) Install a n e w gasket t o the plug.

(c) Install and torque the plug.
Torque: 3 7 5 kg-cm ( 2 7 ft-lb, 3 7 N - m )

2. INSTALL OIL FILTER

(See page LU-5)

INSTALLATION OF OIL FILTER BRACKET

1. INSTALL OIL FILTER BRACKET
(a) Install a n e w O-ring t o bracket.
(b) Install a n e w gasket t o union bolt.
(c) Put the oil filter bracket hole over the cylinder block
stud bolt and install the oil filter bracket w i t h the
union bolt.

(dl Torque the union bolt.

Torque: 5 0 0 kg-cm ( 3 6 ft-lb, 49 Nnm)

(el Connect the oil hose.

LU-18 LUBRICATION SYSTEM - Oil Cooler and Relief Valve (7M-GTE)

2. INSTALL N 0 . 7 AIR CLEANER HOSE

(a) Connect the PS Idle up air hose.
(b) Install t h e No.7 air cleaner hose and bolt.
(c) Tlghten the clamps and lock the alr cleaner case cllps.
( d ) Connect the alr f l o w meter connector
(el Connect the air hoses t o PCV pipe, air Intake connec-
tor and ISC pipe.

EM6252

3. INSTALL N 0 . 4 A I R CLEANER PIPE W I T H N O . l A N D N 0 . 2

AIR CLEANER HOSES

4. START ENGINE A N D CHECK FOR LEAKS